Energy absorption device, especially for non-axial loads

ABSTRACT

The invention relates to an energy absorption device which can be arranged to absorb energy by deformation between a support structure of a vehicle and a damper, the energy absorption device carrying a deformable main profile which has a hollow body-type cross-section. The aim of the invention is to improve an energy absorption device of the aforementioned type in such a manner that the energy can be well carried off even if the forces produced by an accident impact the energy absorption device at an angle. For this purpose, a deformable supplementary profile is provided on the cross-section of the main profile.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from German Patent Application Serial No. 10 2006 048 429.0 filed on Oct. 12, 2006, entitled “Energieabsorptionsvorrichtung, insbesondere für nichtaxiale Belastung” (Energy Absorption Device, In Particular For Non-Axial Loads), the disclosure of which is incorporated herein by reference for all purposes.

FIELD OF THE INVENTION

The present invention relates to an energy absorption device, and more particularly to an energy absorption device which may be situated between a support structure of a vehicle and a bumper to absorb energy by deformation.

BACKGROUND OF THE INVENTION

Energy absorption devices are used for the purpose of absorbing as much energy as possible in the event of an accident, before the vehicle body of the vehicle plastically deforms. In less severe accidents, the energy absorption capability of an energy absorption device may be sufficient to entirely avoid plastic deformation of the vehicle body. The repair costs remain low in this way, because only the bumper and the energy absorption device have to be replaced.

For good energy absorption, it is optimal if the energy absorption devices are implemented as an extension of longitudinal girders of an underbody of the vehicle and the bumper, in particular its crossbeam, is located horizontally at the height of the energy absorption devices. The forces are thus introduced linearly into the energy absorption device, by which its entire length may be used well for the deformation, i.e., absorbing energy.

The vehicle manufacturers have made efforts to bring as many vehicle variants as possible onto the market. To keep the costs as low as possible, the various vehicle variants are constructed on one underbody. If sports utility vehicles or SUVs are constructed on a passenger automobile underbody, the underbody is higher than in the passenger automobile. According to the legal requirements, however, the bumper, in particular its crossbeam, must be located at the height which normally corresponds to a passenger automobile bumper. This means that a Vertical offset between the bumper, in particular its crossbeam, and longitudinal girders of the underbody is to be bridged.

One possibility is to implement the energy absorption device, as up to this point, as a longitudinal extension of the longitudinal girder of the underbody, but provide a bumper with a cross member which extends over the entire vertical area and is implemented as solid. In this way, the forces may be introduced into the energy absorption device well and absorbed thereby.

Employing energy absorption devices according to the species and bridging the offset between the bumper, possibly a cross member thereof, and the longitudinal girder of the underbody, using them is also known. More compact and lighter bumpers, in particular more compact and lighter crossbeams may thus be used, which saves weight. However, tests have shown that accident forces are not conducted linearly enough through these energy absorption devices, which results in poor energy absorption.

SUMMARY OF THE INVENTION

The present invention is based on the object of improving an energy absorption device according to the species in the simplest possible way so that energy may be dissipated well, but nonetheless forces are introduced diagonally into the energy absorption device.

The object is achieved according to the invention by an energy absorption device having the features of Claim 1.

The auxiliary profile stabilizes the main profile of the energy absorption device and particularly counteracts an undesired buckling of the energy absorption device. In this way, the energy absorption device remains stable for the absorption and transmission of forces in spite of forces being introduced diagonally or even transversely. This means that in spite of the diagonally introduced forces, good efficiency of the energy absorption is achieved. In particular in the event of an offset between support structure and bumper, compact and light bumpers are usable. If bumpers are implemented having crossbeams, the crossbeam may be implemented as light and compact.

If the bumper is situated offset to the support structure and the energy absorption device bridges the offset, the auxiliary profile may advantageously stabilize a cross-sectional section of the main profile, which is situated in front in the offset direction. A cross-sectional section of the main profile, which is especially endangered by buckling, is stabilized in this way.

The cross-sectional section may preferably be a lower cross-sectional section of the main profile in relation to the vehicle. Pivoting of the bumper downward in the event of an accident is thus counteracted and the forces are absorbed well.

The auxiliary profile may preferably stabilize an approximately horizontal lateral cross-sectional section of the main profile in relation to the vehicle. A cross-sectional section of the main profile is thus stabilized, which is situated in front in the direction of a transverse component of an accident force, i.e., a cross-sectional section of the main profile which is endangered by buckling by the transverse component of the accident force is stabilized. Energy may thus be absorbed efficiently even in the event of a diagonal frontal impact using the energy absorption device.

The lateral cross-sectional section may especially favorably be an outer cross-sectional section in relation to a longitudinal central direction of the vehicle. This has an especially good stabilizing effect in the event of accident forces which displace the bumper in the cited outward direction.

The auxiliary profile may especially advantageously have an essentially arched cross-section. This provides it with good rigidity against undesired buckling.

The cross-section of the auxiliary profile may especially favorably implement an essentially convex contour with an area of the cross-section of the main profile. The auxiliary profile and the area of the cross-section of the main profile thus have good rigidity against buckling and supplement one another mutually.

The cross-section of the auxiliary profile may advantageously have chamfers. The chamfers have a stabilizing effect against undesired buckling.

The auxiliary profile may preferably be situated in the interior of the main profile. The energy absorption device may thus be implemented in a space-saving way and nonetheless has good stability and good energy absorption capability.

The auxiliary profile may preferably taper in the direction toward the support structure of the vehicle. The energy absorption device is thus more strongly stabilized on the side of the bumper against undesired buckling in the offset direction than on the side of the support structure of the vehicle.

The height of the cross-section of the auxiliary profile may especially advantageously decrease in the direction toward the support structure of the vehicle. In this way, the auxiliary profile has a greater stabilizing effect against undesired buckling in the direction of its height on the side of the bumper than on the side of the support structure of the vehicle.

The auxiliary profile may advantageously taper in the direction toward the bumper. In this way, the energy absorption device is more strongly stabilized against undesired buckling in the direction of the transverse component of the accident force on the side of the support structure than on the side of the bumper.

The height of the cross-section of the auxiliary profile may preferably decrease in the direction toward the bumper. The auxiliary profile thus has a greater stabilizing effect against undesired buckling in the direction of its height on the side of the support structure than on the side of the bumper.

If the bumper is situated offset to the support structure and the energy absorption device bridges the offset, the auxiliary profile may especially favorably have an inclination in relation to a longitudinal direction of the support structure, which is opposite to the direction of the offset. The forces introduced from the bumper may thus be conducted through the energy absorption device having a stronger component parallel to the longitudinal direction of the support structure in spite of the offset.

If the bumper is situated offset to the support structure and the energy absorption device bridges the offset, the auxiliary profile may preferably have a profile back which is inclined opposite to the direction of the offset in relation to the longitudinal direction of the support structure. In this way, forces may be conducted at an angle through the profile back and at least partially compensate for the angularity of forces which are conducted through the main profile. The sum of the forces conducted through the energy absorption device thus approaches the longitudinal direction of the support structure better in its direction.

The auxiliary profile may especially advantageously be laterally inclined horizontally in relation to a longitudinal direction of the support structure. The auxiliary profile is thus inclined corresponding to a transverse component of an accident force to be expected and has an especially good stabilizing effect against undesired buckling in relation to the transverse component.

The auxiliary profile may especially favorably have a profile back which is laterally inclined horizontally in relation to a longitudinal direction of the support structure. In this way, the profile back is inclined corresponding to a transverse component of an accident force to be expected and applies a good stabilization component against undesired buckling in relation to the transverse component.

At least two auxiliary profiles running at a distance to one another may advantageously be provided. The energy absorption device is stabilized even better against undesired buckling using a plurality of auxiliary profiles. Due to the distance between the auxiliary profiles, they may deform without obstruction.

The auxiliary profile may especially preferably be fastened to the main profile over a greater length in an area on the support structure side than in an area on the bumper side. The shorter fastening length in the area on the bumper side makes a deformation of the auxiliary profile and the main profile easier here. The greater fastening length in the area on the support structure side increases the resistances of the auxiliary profile and the main profile to deformation here. The force applied to the support structure may be kept at an essentially constant level.

A transition area may preferably be provided, in which the auxiliary profile is fastened to the main profile over a shorter length than in the area on the support structure side and over a greater length than in the area on the bumper side. In the transition area, the auxiliary profile and the main profile have a moderate resistance against deformation viewed overall, compared to the areas on the support structure and bumper sides. This contributes well to keeping the force applied to the support structure at a constant level.

The auxiliary profile may advantageously be fastened to the main profile over approximately 30% to 45% of its length in the area on the support structure side, preferably over approximately 40% of its length. In this way, the auxiliary profile and the main profile have an increased resistance to deformation in a good area, i.e., a good area which first deforms at higher forces.

The auxiliary profile may especially preferably be fastened to the main profile over approximately 3% to 10% of its length, preferably over approximately 5% of its length, in the area on the bumper side. The auxiliary profile and the main profile thus have a good area in which the resistance to deformation is lower, i.e., which already absorbs energy at lower forces, because auxiliary profile and main profile may fold freely in a good area.

The auxiliary profile may advantageously be fastened to the main profile over approximately 5% to 15% of its length, preferably over approximately 10% of its length, in the transition area. The auxiliary profile and the main profile thus have a good area of moderate resistance to deformation viewed overall, i.e., a good area in which energy is only absorbed at a later point in time.

The auxiliary profile may favorably have a greater material strength on the support structure side than on the bumper side. The auxiliary profile has a higher resistance to deformation on the support structure side than on the bumper side.

The auxiliary profile may preferably have at least two material parts of different material thicknesses. The auxiliary profile thus has a different resistance to deformation in each material part.

The auxiliary profile may advantageously have a material part which has a material thickness varied by rolling. The provision of the areas of different material thicknesses may thus be performed for many workpieces in an efficient process.

The material of the auxiliary profile may advantageously have a higher strength on the support structure side than on the bumper side. The auxiliary profile thus has a lower resistance on the bumper side than on the support structure side.

The auxiliary profile may especially expediently have at least one longitudinal bead extending in its longitudinal direction, preferably in the area proximal to the support structure. In the area of the longitudinal bead, the auxiliary profile has a higher resistance to deformation in its longitudinal direction.

The auxiliary profile may especially preferably have at least one transverse bead extending transversely to its longitudinal direction, preferably in the area close to the bumper. The auxiliary profile may be folded more easily in its longitudinal direction in the area of the transverse bead. The transverse bead defines an area for intentional folding deformation, the energy absorption device as a whole remaining stabilized against undesired buckling.

If the bumper is situated offset to the support structure and the energy absorption device bridges the offset, a first cross-sectional section of the main profile which is situated in front in the offset direction may preferably have a higher deformation resistance than a second cross-sectional section of the main profile which is situated behind the first cross-sectional section in the offset direction. In this way, a cross-sectional section of the main profile, which is endangered by buckling by the structural offset, is stabilized.

A first cross-sectional section of the main profile which is located on a first horizontal side of the energy absorption device in relation to the vehicle may advantageously have a higher deformation resistance than a second cross-sectional section of the main profile which is located on the second horizontal side of the energy absorption device in relation to the vehicle. The anterior cross-sectional section of the main profile in the direction of a transverse component of an accident force is thus stabilized against undesired buckling.

The first cross-sectional section may preferably have a greater material thickness than the second cross-sectional section. The first cross-sectional section thus has a higher resistance to deformation than a second cross-sectional section.

The material of the first cross-sectional section may preferably have a greater material thickness than the second cross-sectional section. The first cross-sectional section thus has a higher resistance to deformation than the second cross-sectional section.

The material of the first cross-sectional section may advantageously have a higher strength than the material of the second cross-sectional section. The second cross-sectional section thus has a lower resistance to deformation than the first cross-sectional section.

More chamfers may advantageously be provided on the first cross-sectional section than on the second cross-sectional section. The first cross-sectional section thus has a higher resistance to deformation than the second cross-sectional section.

The main profile in the intermediate profile may especially preferably be produced from sheet-metal-type material and/or sheet-metal-type profiles. The energy absorption device may thus be implemented having low weight and a high level of design freedom.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the invention is shown in the drawing and described hereafter. In the figures:

FIG. 1 shows a perspective view of energy absorption devices of a first embodiment of the invention between a crossbeam of a bumper and support structures of a vehicle,

FIG. 2 shows a perspective illustration of one of the energy absorption devices according to the invention from FIG. 1,

FIG. 3 shows a perspective illustration of a part of the energy absorption device from FIG. 2,

FIG. 4 shows a schematic sectional view of the energy absorption device between the bumper and one of the support structures according to the first embodiment,

FIG. 5 shows a schematic sectional illustration having alternative orientations of an auxiliary profile of the energy absorption device,

FIG. 6 essentially shows a top view of the part of the energy absorption device from FIG. 3,

FIG. 7 shows, partially and individually, two cross-sectional views of a main profile and an auxiliary profile of the energy absorption device,

FIG. 8 shows a side view of the energy absorption device according to FIG. 1,

FIG. 9 shows a sectional view of the energy absorption device along a line IX-IX in FIG. 8,

FIG. 10 shows a sectional view of the energy absorption device along a line X-X in FIG. 8,

FIG. 11 shows a force-distance diagram of the energy absorption device,

FIG. 12 shows a perspective view of energy absorption devices of a second embodiment of the invention between a crossbeam of a bumper and support structures of a vehicle,

FIG. 13 shows a perspective illustration of one of the energy absorption devices according to the invention from FIG. 12,

FIG. 14 shows a perspective illustration of a part of the energy absorption device from FIG. 13,

FIG. 15 shows a cross-sectional view of the energy absorption device from FIG. 13,

FIG. 16 shows a cross-sectional view of an alternative design of the cross-sectional profile of the energy absorption device,

FIG. 17 shows a partial frontal view of the configuration from FIG. 12,

FIG. 18 shows a schematic sectional view of the energy absorption device between the bumper and one of the support structures along a line XVIII-XVIII in FIG. 17, and

FIG. 19 shows a schematic sectional view of the energy absorption device between the bumper and one of the support structures along a line XIX-XIX in FIG. 17.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Identical reference numerals are used for similar elements in the following description.

FIGS. 1 through 11 relate to a first embodiment of the invention.

FIG. 1 partially shows a vehicle body configuration of a vehicle. The vehicle body configuration has support structures 4, 5, energy absorption devices according to the invention attached thereto, and a bumper, of which only a crossbeam 3 is shown, however. The energy absorption devices are constructed symmetrically to one another and are each situated between the bumper, i.e., crossbeam 3, and the particular support structure. The crossbeam 3 connects the two energy absorption devices 1, 2. The support structures 4, 5 are each longitudinal girders of an underbody or platform of the vehicle in the present embodiment.

The bumper, i.e., the crossbeam 3, is situated offset to the particular support structure. The particular energy absorption device bridges the offset between the crossbeam 3 and the particular support structure 4, 5. The energy absorption devices are fastened, preferably removably, to the relevant support structure 4, 5 via a particular flange 6, 7.

In this embodiment, the offset is vertical. A horizontal offset is additionally or alternatively possible.

The left energy absorption device 1 in FIG. 1 is shown in a perspective view in FIG. 2. It has a deformable main profile 8, like a hollow body in cross-section, which carries the bumper via the crossbeam 3. The main profile may have a closed or open structure like a hollow body.

The main profile 8 has a first cross-sectional section 9 and a second cross-sectional section 10. The first cross-sectional section 9 is situated in front in the offset direction 11 and the second cross-sectional section is situated behind the first cross-sectional section 9 in the offset direction 11. In this embodiment of the invention, the first cross-sectional section 9 is a lower cross-sectional section in relation to the vehicle and the second cross-sectional section 10 is an upper cross-sectional section.

The cross-sectional sections are shell-type components in this embodiment of the invention, which are connected to one another by joining, e.g., welding, and have a shared inner chamber. However, it is also possible to implement the main profile part in one piece.

The energy absorption device has at least one deformable auxiliary profile 12 provided in the cross-section of the main profile 8. The auxiliary profile 12 may be situated inside or outside the main profile 8. It extends in the longitudinal direction of the main profile and stabilizes it against undesired buckling. Thus, in spite of the offset between support structure and crossbeam, accident forces acting essentially parallel to the longitudinal direction of the sport structure may be well accommodated, absorbed, and relayed in the direction toward the support structure, the energy absorption capability of the energy absorption device 1 being able to be exploited well. The auxiliary profile is implemented as shell-like.

The two cross-sectional sections 9, 10 and the auxiliary profile 12 are produced from sheet-metal-type, reshaped material and/or sheet-metal-type profiles, which were possibly reshaped further.

The auxiliary profile 12 may be situated on the first and/or second cross-sectional section 9, 10. In the present embodiment of the invention, it is attached on the first cross-sectional section 9 and stabilizes it against undesired buckling.

As shown in FIGS. 2 and 3, the auxiliary profile has an essentially arched cross-section, which is implemented as approximately U-shaped or C-shaped in this embodiment of the invention. The cross-section of the auxiliary profile 12 has chamfers 59, by which it is additionally stabilized against undesired buckling.

The auxiliary profile 12 forms an essentially convex contour with an area of the cross-section of one of the first and second cross-sectional sections 9, 10, in this embodiment with an area of the cross-section of the first cross-sectional section 9. The rigidities of the first cross-sectional section 9 and auxiliary profile 12 thus supplement one another well.

It is equally possible to attach the auxiliary profile 12 having reversed arched cross-section on the first cross-sectional section. The rigidities of the auxiliary profile and the first cross-sectional section 9 also supplement one another mutually here.

The intermediate profile 12 extends essentially over the entire length of the first cross-sectional section 9. As may be seen from FIGS. 2 and 3, the auxiliary profile 12 is situated inclined in relation to the main profile 8. An end 51 of the intermediate profile 12 on the bumper side is situated approximately centrally in the main profile 8. An end 52 of the intermediate profile 12 on the support structure side is situated in front in the main profile 8 in relation to the offset direction 11. The end 51 on the bumper side is situated in the area of a profile opening 16 of the first cross-sectional section 9, i.e., in a rear area of the first cross-sectional section 9 in relation to the offset direction 11. The end 52 on the support structure side is situated in the area of a profile floor 17 of the first cross-sectional section 9, i.e., in front in the offset direction.

The auxiliary profile 12 extends continuously between the end 51 on the bumper side and the end 52 on the support structure side. A discontinuous course, e.g., an interrupted course, is also possible, however.

As may also be seen from FIG. 4, the auxiliary profile 12 has an inclination which is opposite to the offset direction 11 in relation to a longitudinal direction of the support structure 4. A longitudinal center line 18 of the auxiliary profile 12 runs in the direction toward the crossbeam 3 in relation to a longitudinal center line 19 of the support structure 4, i.e., it encloses a corresponding angle therewith in relation to the offset direction 11. The longitudinal center line 18 of the intermediate profile 12 runs away from a center line 20 of the crossbeam 3 in the direction toward the crossbeam 3 and encloses a corresponding angle therewith in relation to the offset direction 11.

However, it is also possible to orient the intermediate shell 12 parallel to the longitudinal direction of the support structure and/or the crossbeam, i.e., to provide the longitudinal center line 18 of the auxiliary profile running parallel to the longitudinal center line 19 of the support structure and/or the center line 20 of the crossbeam 3. This is illustrated in FIG. 5 with the aid of a longitudinal center line 218 for the auxiliary profile.

The auxiliary profile may just as well be situated with a greater inclination in relation to the longitudinal direction of the support structure 4. This is illustrated in FIG. 5 with the aid of a longitudinal center line 118 for the auxiliary profile.

Reference is again made to FIG. 4. The auxiliary profile 12 has a profile back 21. The profile back 21 is also inclined opposite to the offset direction 11 in relation to the longitudinal direction of the support structure 4. It runs in the direction toward the crossbeam 3 in relation to the longitudinal center line 19 of the support structure 4. It runs more strongly inclined than the longitudinal center line 18 of the auxiliary profile 12.

The auxiliary profile 12 has lateral edges 53, 54, one of which is shown in FIG. 4 and which are situated leading in the offset direction 11. The lateral edge 54 shown runs approximately parallel in relation to the offset direction to the longitudinal center line of the support structure 4 and the center line 20 of the crossbeam 3.

The auxiliary profile 12 tapers in the direction toward the support structure 4. The height of the cross-section of the auxiliary profile 12 decreases in the direction toward the support structure 4, as may be seen from FIG. 4. The width of the auxiliary profile 12 also decreases, as shown in FIG. 6.

It is also possible that the auxiliary profile essentially maintains its width and/or height over its length. In addition, it is possible that the width and/or height of the auxiliary profile increases in the direction toward the support structure 4.

Welded bonds 55, 56, 57, 58, using which the second cross-sectional section 10, the intermediate profile 12, and the first cross-sectional section 9 are fastened to the crossbeam 3, are also shown in FIG. 4. Furthermore, it may be seen from FIG. 4 that the intermediate profile 12 extends in the direction toward the support structure 4 up into an area of the flange 6. The auxiliary profile 12 is welded on the flange 6 or is supported freely thereon, as shown in FIG. 4.

Reference is made to FIG. 6. The auxiliary profile 12 is fastened on the main profile 8, i.e., on the first cross-sectional section 9, over a greater length on the support structure side than on the bumper side. In this embodiment of the invention, a transition area 15 is also provided between the area 14 on the support structure side and the area 13 on the bumper side of the auxiliary profile 12, in which the auxiliary profile 12 is fastened on the main profile 8 over a shorter length than in the area 14 on the support structure side and over a greater length than in the area 13 on the bumper side.

With this design of the fastenings, the auxiliary profile 12 folds successively from the crossbeam 3 up to the support structure 4. The force level applied to the support structure 4 remains essentially constant.

Because the auxiliary profile 12 is fastened at least on the main profile 8, i.e., on the first cross-sectional section 9, in the area 13 on the bumper side, it may fold most freely here in the event of a deformation. The deformation resistance is thus lowest in relation to the fastening here. In the area 14 on the support structure side, the deformation resistance is highest in relation to the fastening, because the auxiliary profile 12 is fixed on the main profile over the largest area here. In the transition area 15, the deformation resistance in regard to the fastening is between that of the area 14 on the support structure side and that of the area 13 on the bumper side.

Welded bonds 22, using which the auxiliary profile 12 is fastened on the main profile 8, i.e., on the first cross-sectional section 9, over 30% to 45% of its length, preferably over approximately 40% of its length, are provided on both sides on the support structure side. The auxiliary profile is fastened over approximately 3% to 10% of its length, e.g., over 5 to 20 mm, on the main profile 8, i.e., on the first cross-sectional profile 9, preferably over approximately 5% of its length, e.g., over 10 mm, as shown in FIG. 6, using welded bonds 23 provided on both sides on the bumper side.

Central welded bonds 24, 24 are provided on both sides between the welded bonds 22, 22 on the support structure side and the welded bonds 23, 23 on the bumper side, using which the auxiliary profile is attached on the main profile 8 over approximately 5% to 15% of its length, e.g., over 15 to 30 mm, preferably over approximately 10% of its length, e.g., over 20 mm, as shown in FIG. 6.

The fastenings, i.e., the welded bonds 22, 22; 23, 23; 24, 24 may be implemented continuously or interrupted, e.g., as spot welds.

The fastenings, i.e., the welded bonds 22, 22; 23, 23; 24, 24, extend essentially in the longitudinal direction of the auxiliary profile 12. Good folding is thus achieved and this contributes to a uniform level of the force applied to the support structure. The folds run essentially transversely to the longitudinal direction of the auxiliary profile 12.

An interval 25, 25, which extends over approximately 5% to 15% of the length of the intermediate profile 12, e.g., over 15 to 30 mm, preferably over approximately 10% of its length, e.g., over 20 mm, is provided between the welded bonds 22, 22 on the support structure side and the central welded bonds 24, 24 in each case. An interval 26, 26, which extends over approximately 30% to 45% of the length of the auxiliary profile 12, preferably over approximately 30% to 40% of the length, is provided between the welded bonds 23, 23 on the bumper side and the central welded bonds 24, 24 in each case, as shown in FIG. 6. The left interval 26 shown in FIG. 6 is shorter than the right interval in this figure.

It is possible to provide still further intervals and/or welded bonds.

An interval is also provided between the welded bonds 23, 23 on the bumper side and a terminal edge 27 of the auxiliary profile 12 on the bumper side, as shown in the figure. The welded bonds 22, 22 on the support structure side extend up to a terminal edge 28 of the intermediate profile 12 on the support structure side.

In the area of the cited intervals, the intermediate profile may fold freely upon deformation in relation to the first cross-sectional section 9.

Upon the selection of the length of the fastenings, i.e., welded bonds, and the intervals, the total length of the energy absorption device, the cross-section of the energy absorption device, the material thickness, the strength of the material, and the forces to be transmitted are taken into consideration.

Multiple auxiliary profiles may be provided in an energy absorption device according to the invention. They are preferably situated at intervals from one another to be able to deform independently from one another. In spite of the interval, the auxiliary profiles may be fastened jointly to the main profile, for example, welded jointly to the main profile and having lateral edges situated one above another.

The auxiliary profile 12 may have a greater material thickness on the support structure side than on the bumper side. The greater material thickness on the support structure side provides the auxiliary profile 12 with a greater resistance to deformation here than on the bumper side. The auxiliary profile 12 may be constructed from at least two material parts of different material thicknesses. The material parts may be welded together.

It is also possible to implement the auxiliary profile 12 having a material part which has a material thickness varied by rolling. The material thickness may vary fluidly, by which the resistance against deformation changes fluidly. The material thickness may be varied flexibly upon rolling, in particular in regard to the position of specific material thicknesses.

The material of the auxiliary profile 12 may have a higher strength on the support structure side than on the bumper side. This is a further possibility for implementing the auxiliary profile 12 having a higher strength against deformation on the support structure side.

The cited different material thicknesses and strengths of the material may be implemented by employing so-called tailored blanks, whether they are welded or rolled.

As shown in FIG. 7, the auxiliary profile 12 has a longitudinal bead 29, which is implemented in an area 14 on the support structure side and extends approximately in the longitudinal direction. The longitudinal bead 29 is shaped into the profile back 21 and implemented as depressed in the direction toward an inner chamber of the auxiliary profile 12. It increases the deformation resistance of the auxiliary profile 12 against a deformation in its longitudinal direction.

In the area 13 on the bumper side, the auxiliary profile 12 has two transverse beads 30, 31 extending approximately transversely to its longitudinal direction. The transverse beads 30, 31 are implemented as depressed in the direction toward the inner chamber of the auxiliary profile 12. Three or four transverse beads may also be provided.

In the transition area 15, the auxiliary profile 12 has a transverse bead 32 extending approximately transversely to its longitudinal direction, which is implemented as raised away from the inner chamber in this embodiment. The interval of this transverse bead 32 to its adjacent transverse bead 30 in the area 13 on the bumper side is greater in this embodiment of the invention than the interval of the transverse beads 30, 31 in the area on the bumper side to one another.

The transverse beads 30, 31, 32 decrease the deformation resistance of the auxiliary profile 12 against a deformation in its longitudinal direction. They encourage a desired unfolding of the auxiliary profile 12.

Using the measures described above, which may also be applied partially or individually, the auxiliary profile is implemented having lower deformation resistance in the direction toward the bumper than in the direction toward the support structure. These measures may also be applied to the first cross-sectional section 9 and/or the second cross-sectional section 10 of the main profile 8, and also partially or individually. The first cross-sectional section 9 and/or the second cross-sectional section 10 may also have a greater material thickness on the support structure side than on the bumper side, have a material of higher strength on the support structure side than on the bumper side, have at least one longitudinal bead, and/or have at least one transverse bead, as described for the auxiliary profile 12.

The first cross-sectional section 9 and the second cross-sectional section 10 are shown having beads in FIG. 7 for exemplary purposes. The first cross-sectional section 9 has transverse beads extending approximately transversely to its longitudinal direction in an area which approximately corresponds to the transition area 15 of the auxiliary profile 12. A first transverse bead 33 is shaped into the profile floor 17 of the first cross-sectional section 9 and implemented as raised toward the interior of the first cross-sectional section 9 in this embodiment. A second transverse bead 35 is shaped into a side wall 34 of the first cross-sectional section 9 adjacent thereto, which is also implemented as raised in this embodiment toward the interior of the first cross-sectional section 9.

The first cross-sectional section 9 has a bead extending approximately transversely or diagonally to its longitudinal direction on an end 36 on the bumper side, which runs essentially parallel to the terminal edge 38 of the end 36 on the bumper side. This bead is implemented as depressed away from the interior of the first cross-sectional section 9 in this embodiment.

In an area which corresponds to the area 14 of the auxiliary profile 12 on the support structure side, the first cross-sectional section 9 has a longitudinal bead 39 implemented in its profile floor 17 and extending in the longitudinal direction. The longitudinal bead is implemented as raised toward the interior of the first cross-sectional section 9 in this embodiment.

The second cross-sectional section 10 has a first transverse bead 41 in its profile back 40, implemented as corresponding to the first transverse bead 33 of the first cross-sectional section 9, which is implemented as raised in the direction toward an interior of the second cross-sectional section 10 in this embodiment. Adjacent to this first transverse bead 41, a second transverse bead 43 is shaped into a side wall 42 of the first cross-sectional section 10 corresponding to the second transverse bead 35 of the first cross-sectional section 9.

Starting from the first transverse bead 41 of the second cross-sectional section 10, the profile of the profile back 40 passes into a third cross-sectional bead 44 bulging in the opposite direction to the first transverse bead. The longitudinal position at which the first transverse bead 41 passes into the third transverse bead 44 corresponds in this embodiment of the invention to the longitudinal position of the second transverse bead 43 implemented in the side wall 42.

A bead 46 running diagonally or approximately transversely to the longitudinal direction of the second cross-sectional section 10 is implemented in the profile back 40 of the second cross-sectional section 10 on an end 45 on the bumper side. This bead 46 is depressed in the direction toward the interior of the second cross-sectional section 10 in this embodiment and is located in an area close to the third transverse bead 44 of the second cross-sectional section 10, as shown in FIG. 7.

The direction in which the relevant desired folding is implemented is determined by the direction of the arching of the transverse beads.

Measures have been described above, using which the intermediate profile and/or the first cross-sectional section and/or the second cross-sectional section are implemented having a lower deformation resistance on the bumper side than on the support structure side. These measures each contribute to the force, which is exerted on the support structure 4 during the deformation of the energy absorption device according to the invention, remaining essentially constant.

It is also possible to provide the lower deformation resistance on the support structure side and the higher deformation resistance on the bumper side.

An asymmetry exists between the deformation resistance of the first cross-sectional section and that of the second cross-sectional section. The first cross-sectional section 9 of the main profile is implemented overall having a higher deformation resistance, in particular against undesired buckling, than a second cross-sectional section 10. For example, in contrast to the second cross-sectional section 10, it has the longitudinal bead 29. It may also have a greater material thickness and/or material of greater strength than the second cross-sectional section 10 and/or have more chamfers.

Cross-sectional views of the energy absorption device along lines IX-IX and X-X of the side view of FIG. 8 are shown in FIGS. 9 and 10. The greater material thickness of the first cross-sectional section 9 in relation to the second cross-sectional section 10 is schematically illustrated therein.

As shown in FIGS. 9 and 10, the cross-sectional shapes of the first and second cross-sectional sections are fundamentally different. The cross-sectional profile of the first cross-sectional section 9 has more chamfers 47 than the second cross-sectional profile, although both cross-sectional profiles have an essentially U-shaped or C-shaped cross-section. In the present exemplary embodiment, the first cross-sectional section 9 has six chamfers 47 and the second cross-sectional section 10 has four chamfers 48, i.e., the first cross-sectional section 9 is more rigid in this regard than the second cross-sectional section 10.

A force-distance diagram of the energy absorption device 1 according to the invention is shown in FIG. 11. An ideal curve 50 is plotted by linear, bold lines adjacent to the graphs 49 which show the measurement result. The ideal curve 50 corresponds to 100% energy absorption efficiency. As may be inferred from the illustration, an energy absorption efficiency of approximately 90% is achieved using the energy absorption device 1 according to the invention, i.e., the energy absorption device absorbs non-axial loads with good efficiency. The force applied to the support structure 4 remains essentially at equal level.

In the embodiment described above, the bumper 3 is offset to the support structure 4, 5 of the vehicle and the energy absorption device 1, 2 bridges the offset 11. However, it is also possible to use the present invention in an energy absorption device which extends essentially in the longitudinal direction of the support structure 4, 5 of the vehicle. A lateral cross-sectional section of the main profile is stabilized using an auxiliary profile. In this way, accident forces acting at an angle to the longitudinal axis of the vehicle and/or to the longitudinal direction of the support structure may be absorbed with good efficiency by the energy absorption device. For example, this is well possible for an angularity of approximately 0 to 40°, in particular up to 30°. In spite of the angularity of the forces, the energy absorption device remains stable for the absorption and transmission of forces.

The second embodiment of the invention is shown in FIGS. 12 to 19. The essential differences to the first embodiment of the invention are explained hereafter.

In the second embodiment of the invention, the energy absorption devices 301, 302 are provided extending essentially in the longitudinal direction of the support structures 4, 5, i.e., longitudinal girders. The energy absorption devices 301, 302 are thus implemented as an extension of the support structures 4, 5.

The energy absorption devices 301, 302 are constructed essentially symmetrically to one another. Therefore, only the left absorption device 301 in FIG. 12 is described hereafter.

As may be seen from FIGS. 12 and 13, the energy absorption device 301 has two cross-sectional sections 309, 310, which are situated laterally approximately horizontally in relation to the vehicle. The first cross-sectional section 309, i.e., the left cross-sectional section in FIG. 13, is situated on the outside in relation to a longitudinal central direction 361 of the vehicle. The second cross-sectional section 310, i.e., the right cross-sectional section in FIG. 13, is situated on the inside in relation to the longitudinal central direction 361.

An accident force 366 acting at an angle to the longitudinal central direction 361, which is composed of a transverse component 364 and a longitudinal component 365, is illustrated in FIG. 12.

In the second embodiment of the invention, the first cross-sectional section 309 is stabilized against an undesired buckling by the transverse component 364 of the accident force 366 with the aid of an auxiliary profile 312 shown in FIG. 13. The cross-sectional section of the energy absorption device which is anterior in the direction of the transverse component 364 of the accident force 366 is thus stabilized.

In other words, the cross-sectional section situated in front in the offset direction is stabilized by the auxiliary profile. In the second embodiment of the invention, the offset is reflected in the transverse component 364 of the accident force 366, while in contrast a structural offset is provided in the first embodiment of the invention.

It may be seen from FIGS. 13 and 14 how the auxiliary profile 312 is implemented and situated in the main profile 308 formed from first cross-sectional section 309 and second cross-sectional section 310. The auxiliary profile 312 runs, viewed in the longitudinal direction of the energy absorption device 301, at an angle to the first cross-sectional section 309, i.e., laterally inclined horizontally in relation to the longitudinal direction of the support structure 4. The lateral edges 353, 354 of the auxiliary profile 312 run at a greater angle in relation to the profile back 367 of the first cross-sectional section 309 than a profile back 321 of the auxiliary profile 312. The interval between the profile back 367 of the first cross-sectional section 309 and the auxiliary profile 312, in particular its profile back 321, increases in the direction of the support structure 4. The auxiliary profile 312 and its profile back 321 are thus laterally inclined horizontally in relation to the vehicle in the direction of the transverse component 364 of the expected accident force 366.

The cross-section of the energy absorption device, as it is implemented approximately in the area of its longitudinal center, is shown in FIG. 15. The auxiliary profile 312 forms an essentially concave-convex contour with the first cross-sectional section 309. As may be seen from FIG. 16, it is also possible that the auxiliary profile 312 implements an essentially convex contour with the first cross-sectional section 309.

The measures described for the first embodiment of the invention for designing the deformation resistance and/or the deformation behavior of the energy absorption device and/or its elements are similarly applicable in the second embodiment of the invention. Thus, for example, in the second embodiment of the invention, the first cross-sectional section 309 also has a higher deformation resistance than the second cross-sectional section 310. The anterior cross-sectional section in the direction of the transverse component 364 of the accident force 366 is thus already stabilized against undesired buckling in addition to the reinforcement by the auxiliary profile 312.

As in the first embodiment of the invention, the first cross-sectional section 309 has more chamfers than the second cross-sectional section 310. In this embodiment of the invention, the first cross-sectional section 309 has four chamfers 347, while in contrast the second cross-sectional section 310 has two chamfers 348. In contrast to the first embodiment of the invention, the chamfers of the first cross-sectional section 309 run significantly away from one another in the direction of the support structure 304, as shown in FIG. 13.

A schematic sectional view of the energy absorption device 301 along a line XVIII-XVIII in FIG. 17 is shown in FIG. 18, the course of the sectional faces being illustrated. As may be seen from FIG. 18, the energy absorption device tapers toward the bumper, i.e., the crossbeam 3, in the vertical direction.

FIG. 19 is a sectional view of the energy absorption device 301 along a line XIX-XIX in FIG. 17, the course of the sectional faces being illustrated. As shown in FIG. 19, the energy absorption device 301 essentially maintains its horizontal width in the direction toward the bumper, i.e., toward the crossbeam 3.

In the second embodiment of the invention, the first cross-sectional section and the auxiliary profile 312 are provided horizontally on the exterior. It is also possible to provide the first cross-sectional section 309 and/or the auxiliary profile 312 horizontally on the interior. The energy absorption device may thus be stabilized in particular against undesired buckling as a result of accident forces, in which the transverse component is directed opposite to the transverse component 364 shown in FIG. 12.

Similarly good energy absorption efficiency as in the first embodiment, i.e., similarly good efficiency as shown in FIG. 11, is achieved using the energy absorption device of the second embodiment of the invention.

In addition, it is possible to combine the designs of the first and second embodiments with one another. I.e., in the event of a structural offset between support structure and crossbeam of the bumper, stabilization may additionally be provided against buckling as a result of accident forces acting at an angle to the vehicle.

The energy absorption devices according to the invention are also usable with bumpers without crossbeams. 

1-35. (canceled)
 36. An energy absorption device (1, 2, 301, 302), which may be situated between a support structure (4, 5) of a vehicle and a bumper (3) to absorb energy by deformation, the energy absorption device having a deformable main profile (8,308), which is like a hollow body in cross-section and carries the bumper (3), wherein a deformable auxiliary profile (12, 312) is provided on the main profile (8, 308) in cross-section.
 37. The energy absorption device according to claim 36, the bumper (3) being situated offset to the support structure (4, 5) and the energy absorption device bridging the offset, and wherein the auxiliary profile (12) stabilizes a cross-sectional section (9) of the main profile (8) which is situated in front in the offset direction (11).
 38. The energy absorption device according to claim 37, wherein the cross-sectional section is a lower cross-sectional section (9) of the main profile (8) in relation to the vehicle.
 39. The energy absorption device according to claim 37, wherein the auxiliary profile (312) stabilizes a lateral cross-sectional section (309) of the main profile (308) which is approximately horizontal in relation to the vehicle.
 40. The energy absorption device according to claim 39, wherein the lateral cross-sectional section (309) is an outer cross-sectional section in relation to a longitudinal central direction (361) of the vehicle.
 41. The energy absorption device according to claim 36, wherein the auxiliary profile (12, 312) has an essentially arched cross-section.
 42. The energy absorption device according to claim 41, wherein the cross-section of the auxiliary profile forms an essentially convex contour with an area of the cross-section of the main profile (8).
 43. The energy absorption device according to claim 41, wherein the cross-section of the auxiliary profile (12, 312) has chamfers (59, 359).
 44. The energy absorption device according to claim 36, wherein the auxiliary profile (12, 312) is situated in the interior of the main profile (8, 308).
 45. The energy absorption device according to claim 36, wherein the auxiliary profile (12) tapers in the direction toward the support structure (4) of the vehicle.
 46. The energy absorption device according to claim 45, wherein the height of the cross-section of the auxiliary profile (12) decreases in the direction toward the support structure (4) of the vehicle.
 47. The energy absorption device according to claim 36, wherein the auxiliary profile (312) tapers in the direction toward the bumper (3).
 48. The energy absorption device according to claim 47, wherein the height of the cross-section of the auxiliary profile (312) decreases in the direction toward the bumper (3).
 49. The energy absorption device according to claim 36, the bumper (3) being situated offset to the support structure (4, 5) and the energy absorption device bridging the offset, and wherein the auxiliary profile (12) has an inclination, which is opposite to the direction of the offset (11), in relation to a longitudinal direction of the support structure (4).
 50. The energy absorption device according to claim 49, the bumper (3) being situated offset to the support structure (4, 5) and the energy absorption device bridging the offset, wherein the auxiliary profile (12) has a profile back (21) which is inclined opposite to the direction of the offset (11) in relation to the longitudinal direction of the support structure (4).
 51. The energy absorption device according to claim 36, wherein the auxiliary profile (312) is laterally inclined horizontally in relation to a longitudinal direction of the support structure (4).
 52. The energy absorption device according to claim 51, wherein the auxiliary profile (312) has a profile back (321) which is laterally inclined horizontally in relation to a longitudinal direction of the support structure (4).
 53. The energy absorption device according to claim 36, wherein at least two auxiliary profiles (12, 312) running at an interval to one another are provided.
 54. The energy absorption device according to claim 36, wherein the auxiliary profile (12, 312) is fastened to the main profile (8, 308) over a greater length in an area (13) on the support structure side than in an area (14) on the bumper side.
 55. The energy absorption device according to claim 54, wherein a transition area (15) is provided, in which the auxiliary profile (12, 312) is fastened to the main profile (8, 308) over a shorter length than in the area (13) on the support structure side and over a greater length than in the area (14) on the bumper side.
 56. The energy absorption device according to claim 55, wherein the auxiliary profile (12, 312) is fastened on the main profile (8,308) over approximately 30% to 45% of its length in the area (13) on the support structure side.
 57. The energy absorption device according to claim 56, wherein the auxiliary profile (12, 312) is fastened on the main profile (8,308) over approximately 40% of its length in the area (13) on the support structure side.
 58. The energy absorption device according to claim 54, wherein the auxiliary profile (12, 312) is fastened on the main profile (8,308) over approximately 3% to 10% of its length in the area (14) on the bumper side.
 59. The energy absorption device according to at least one of claim 58, wherein the auxiliary profile (12, 312) is fastened on the main profile (8,308) over approximately 5% of its length in the area (14) on the bumper side.
 60. The energy absorption device according to claim 55, wherein the auxiliary profile (12, 312) is fastened on the main profile (8, 308) over approximately 5% to 15% of its length in the transition area (15).
 61. The energy absorption device according to claim 60, wherein the auxiliary profile (12, 312) is fastened on the main profile (8, 308) over approximately 10% of its length in the transition area (15).
 62. The energy absorption device according to claim 36, wherein the auxiliary profile (12, 312) has a greater material thickness on the support structure side than on the bumper side.
 63. The energy absorption device according to claim 62, wherein the auxiliary profile (12, 312) has at least two material parts of different material thicknesses.
 64. The energy absorption device according to claim 62, wherein the auxiliary profile (12, 312) has a material part which has a material thickness varied by rolling.
 65. The energy absorption device according to claim 36, wherein the material of the auxiliary profile (12, 312) has a higher strength on the support structure side than on the bumper side.
 66. The energy absorption device according to claim 36, wherein the auxiliary profile (12) has at least one longitudinal bead (29) extending in its longitudinal direction.
 67. The energy absorption device according to claim 66, wherein the auxiliary profile (12) has at least one longitudinal bead (29) extending in its longitudinal direction, in the area proximal to the support structure (4).
 68. The energy absorption device according to claim 36, wherein the auxiliary profile (12) has at least one transverse bead (33, 35, 37) extending transversely to its longitudinal direction.
 69. The energy absorption device according to claim 68, wherein the auxiliary profile (12) has at least one transverse bead (33, 35, 37) extending transversely to its longitudinal direction, in the area proximal to the bumper (3).
 70. The energy absorption device according to claim 36, the bumper (3) being situated offset to the support structure (4, 5) and the energy absorption device bridging the offset, and wherein a first cross-sectional section (9) of the main profile (8), which is situated in front in the offset direction (11), has a higher deformation resistance than a second cross-sectional section (10) of the main profile (8), which is situated behind the first cross-sectional section in the offset direction (11).
 71. The energy absorption device according to claim 36, wherein a first cross-sectional section (309) of the main profile (308), which is located on a first horizontal side of the energy absorption device (301) in relation to the vehicle, has a higher deformation resistance than a second cross-sectional section (310) of the main profile (308), which is located on a second horizontal side of the energy absorption device in relation to the vehicle.
 72. The energy absorption device according to claim 70, wherein the first cross-sectional section (9) has a greater material thickness than the second cross-sectional section (10).
 73. The energy absorption device according to claim 71, wherein the first cross-sectional section (9) has a greater material thickness than the second cross-sectional section (10).
 74. The energy absorption device according to claim 70, wherein the material of the first cross-sectional section (9) has a higher strength than the material of the second cross-sectional section (10).
 75. The energy absorption device according to claim 71, wherein the material of the first cross-sectional section (9) has a higher strength than the material of the second cross-sectional section (10).
 76. The energy absorption device according to claim 70, wherein more chamfers (47) are provided on the first cross-sectional section (9) than on the second cross-sectional section (10).
 77. The energy absorption device according to claim 71, wherein more chamfers (47) are provided on the first cross-sectional section (9) than on the second cross-sectional section (10).
 78. The energy absorption device according to claim 36, wherein the main profile (8) and the intermediate profile (12) are produced from sheet-metal-type material and/or sheet-metal-type profiles. 